Foamalux product guide

SHEET ROOFING MATERIALSC1 (SFB) / 37JULY 2002MARLON CS LONGLIFEFOAMALUX & FOAMALUX ULTRAPLANCHAS DERIGID FOAM PVC SHEETSPOLICARBONATOONDULADASPERFORMANCEESPECIFICACIONES Y& FUNCIONES SPECIFICATION DEL PRODUCTODESIGN FACTORES DE DISENOPROCESSINGINSTALACIONMARLON FOAMALUX CSP R O D U C T G U I D E

Brett Martin is a multi-site international organisationproducing comprehensive ranges of semi-finished plasticproducts, rooflight sheeting materials and plasticdrainage products.Our reputation for excellence in product qualityand technical service is built on over 40 yearsmanufacturing experience.

BRETT MARTINPRODUCT MANUALSP R O D U C T G U I D EBrett Martin is a leading European producer ofplastic sheet products and manufactures Europe's largestrange of rooflight sheeting and glazing products.Brett Martin has many years of experiencein the production of GRP, PVC and Polycarbonatesheet products, on the basis of which Foamalux and FoamaluxUltra extruded rigid foam PVC sheets area natural product development.Foamalux, rigid foam PVC sheet, exhibits an excellentrange of properties - a satin smooth surface finish,a range of vibrant colours, superior fire performanceand easy workability. Foamalux has the most comprehensivecolour and thickness range manufacturedin the UK. Foamalux Ultra, gloss foam PVC sheet,combines the same excellent combination ofproperties with a superb gloss surface.Foamalux and Foamalux Ultra, in common with allBrett Martin products, are manufactured to standardsof excellence which have earned Brett MartinBSI Registered status under BS EN ISO 9002.

FOAMALUXPRODUCTGUIDECONTENTSPRODUCT GUIDEBRETT MARTIN 4FOAMALUX & FOAMALUX ULTRA 4APPLICATIONS 5PRODUCT GUIDE 5SPECIFICATION& PERFORMANCEPHYSICAL CHARACTERISTICS 8THERMAL PROPERTIES 8ELECTRICAL PROPERTIES 8ACOUSTIC PROPERTIES 8SHEET SIZES & TOLERANCES 8FIRE PERFORMANCE 9SURFACE PROTECTION & PACKAGING 9STORAGE 9HANDLING 10SAFETY 10WASTE DISPOSAL 10DESIGN FACTORSSUNLIGHT 12THERMAL MOVEMENT 13LOW TEMPERATURES 13WIND LOADING 14PRECIPITATION 14CHEMICAL & ENVIRONMENTAL ATTACK 14COMPONENT GEOMETRY 14PANEL ORIENTATION 15MACHINING OPERATIONSPageCUTTING, SHAPING & FINISHING 18CUTTING 18GUILLOTINING 18DIE CUTTING 18SAWING 18DRILLING 19MILLING & ROUTING 19FINISHING 19FORMING, FABRICATION& BONDINGFOLDING 22DRAPE FORMING 23THERMOFORMING 23HOT AIR WELDING 25HOT PLATE WELDING 26STRUCTURES & FRAMES 26MECHANICAL FASTENING 27ADHESIVES 28SUBSTRATE APPLICATIONSSHEET PREPARATION 30STATIC ELECTRICITY 30TOLERANCES 30PAINTING & VARNISHING 30VINYL GRAPHICS 31LAMINATION 31PRINTING 31AppendicesAPPENDIX 1 - THERMAL MOVEMENTCALCULATIONS 34APPENDIX 2 - CHEMICAL RESISTANCE 36APPENDIX 3 - ADHESIVES MANUFACTURERS 40INK MANUFACTURERS 40APPENDIX 4 - HOLE, SLOT & WASHER SIZES 40IMPORTANT NOTE ONSEMI FINISHED MATERIALSSince the end uses of semi finished materials areso diverse it is the responsibilty of each user ofBrett Martin’s Foam PVC Sheets to make hisown tests to determine the material’s suitabilityfor his own particular use.All the information is given in good faith butwithout commitment and warranty given orimplied. Brett Martin accepts no liability fordefects, loss or damage resulting from misuse,improper installation, inappropriate specificationor any other factor beyond its control.PageIn accordance with our company’s policyof continual product development, you areadvised to check with your local Brett Martinrepresentative to ensure that you haveobtained the most up to date information.2

FOAMALUXPRODUCTGUIDEINDEXPRODUCT GUIDEPRODUCT GUIDEBRETT MARTINPage4FOAMALUX & FOAMALUX ULTRA 4APPLICATIONS 5PRODUCT GUIDE 53

FOAMALUXPRODUCTGUIDEBRETT MARTINFOAMALUX & FOAMALUX ULTRABRETT MARTINBrett Martin is an international multi-sitemanufacturing company, specialising in plastic sheetproducts including PVC, GRP and Polycarbonate.The Brett Martin range is one of the largest inEurope and is available from specialist distributorsthroughout the UK and in an increasing number ofcountries around the world.Brett Martin Ltd is listed on the BSI Register of Firmsof Assessed Capability under BS EN ISO 9002.FOAMALUXFoamalux, rigid foam PVC sheet, is ideal for use ina wide variety of indoor and short term outdoorapplications. It is an extruded, unplasticised PVCfoam sheet with a smooth semi-matt surface finish.FOAMALUX ULTRAFoamalux Ultra, rigid gloss foam PVC sheet,combines the cost and weight advantages of foamPVC with a superb gloss top surface. It is anextruded, closed cell, unplasticised PVC foamsheet with a co-extruded surface layer of UVstabilised PVC which forms an integral part of thesheet. Foamalux Ultra has better UV stability thanstandard foam PVC.FOAMALUX & FOAMALUX ULTRAFoamalux and Foamalux Ultra have very similarproduct characteristics and are therefore dealt withtogether throughout this product guide, with anydifferences being highlighted within the relevantsection. These two materials possess an impressiverange of properties and advantages:• The optimum surfaces - Foamalux hasa uniform closed cell structure with a satin finish.Foamalux Ultra has a smooth, hard, high glosssurface layer, co-extruded on the Foamaluxsubstrate. Their uniformity in surface finishand colouring is of superior quality for all typesof processing, giving outstanding results wheresubstrate surface quality is critical, eg. in screenprinting, application of vinyl graphics andphotographic print mounting.• Design versatility - Foamalux andFoamalux Ultra offer extensive choices tothe designer, who can exploit many original waysof using white and coloured materials in glossor satin finishes to produce stimulating signs,displays, in-store graphics and merchandising.• Lightweight - Foamalux and Foamalux Ultraare approximately half the weight of solid PVCsheet, so are ideal for constructing displays andexhibitions where portability is important. Theyare more cost effective than solid rigid materials.• Consistency - Production controls ensureuniformity of surface finish, thickness, colour, cellstructure and density across the Foamalux ranges.Tolerances on all these parameters are set withinstrict limits.4

FOAMALUXPRODUCTGUIDEAPPLICATIONSPRODUCT GUIDE• Strength and durability - The size anduniformity of the closed cell structure is designedto give an ideal combination of strengthand durability. The surfaces of both Foamaluxand Foamalux Ultra have excellent resistanceto knocks and scratches. The closed cell structureminimises water absorption, ensuring that thestructure of the sheet will not deteriorate whenused in exterior applications.• Workability - Basic wood and metal workingtools are suitable for cutting, shaping and drillingFoamalux and Foamalux Ultra. They can becurved and bent, thermoformed, bonded, gluedand mechanically fixed very successfully whenappropriate procedures are followed.• Product RangeFoamaluxWIDTH WHITE COLOURS1220mm x 2440mm 1, 2, 3, 4, 5, 6, 8,10 &13mm 3 & 5mm1220mm x 3050mm 3 & 5mm -1560mm x 3050mm 2, 3, 4, 5, 6, 8 & 10mm -2050mm x 3050mm 2, 3, 4, 5, 6, 8 & 10mm *3 & 5mm*Please contact Brett Martin for details of colours available.Foamalux UltraWIDTH WHITE COLOURS1220mm x 2440mm 3, 5, &10mm 3 & 5mmThe range is expanding to meet market demandsand alternative options may be available subjectto minimum order quantities. Please consultBrett Martin for up to date range information.APPLICATIONSUses of Foamalux and Foamalux Ultra derive fromtheir visual qualities combined with consistency,lightness, easy workability, excellent fire performanceand chemical resistance. They include:• SCREEN PRINTING• VINYL GRAPHICS SUBSTRATES• PHOTOGRAPHIC MOUNTING• SIGNS & SIGN LETTERING• CEILING TILES• DECORATIVE PANELS• DISPLAYS• POINT OF SALE, DISPLAY& MERCHANDISING EQUIPMENT• EXHIBITION SYSTEMS• CONTAINERS• MODELS• CHEMICAL RESISTING SURFACES• INSULATION SANDWICH PANELS• ENCLOSURES• EQUIPMENT COVERS• FURNITURE COMPONENTS• ETC.PRODUCT GUIDEThe Foamalux Product Guide contains informationon product specifications and performance, uses,design criteria, machining, fabricating and installationinstructions to ensure successful use of Foamaluxand Foamalux Ultra in almost every application.• Fire rating - Foamalux and Foamalux Ultrahave been tested in accordance withBS 476: Part 7: 1987 and have achieved Class 1Surface Spread of Flame designations. Testing inaccordance with other European standards hasalso produced high classifications.• Chemical and environmental resistance -Foamalux and Foamalux Ultra are resistant todilute acids and alkalis, do not corrode or rotand are not prone to attack by pests.5

FOAMALUXPRODUCTGUIDEINDEXSPECIFICATION & PERFORMANCESPECIFICATION& PERFORMANCEPageMATERIAL PROPERTIES 8PHYSICAL CHARACTERISTICS 8THERMAL PROPERTIES 8ELECTRICAL PROPERTIES 8ACOUSTIC PROPERTIES 8SHEET SIZES & TOLERANCES 8FIRE PERFORMANCE 9SURFACE PROTECTION & PACKAGING 9STORAGE 9HANDLING 10SAFETY 10WASTE DISPOSAL 107

FOAMALUXPRODUCTGUIDEMATERIAL PROPERTIESFOAMALUX & FOAMALUX ULTRAMATERIAL PROPERTIESThe properties listed are typical values obtained bytesting large numbers of specimens under specifiedconditions and procedures. As additional processingof the sheet can influence the material properties,the information given should be treated with cautionwhen applied to finished products. Unless otherwisespecified the properties apply to both Foamaluxand Foamalux Ultra.PHYSICAL CHARACTERISTICSCharacteristic Foamalux Foamalux UltraBase polymer: Polyvinyl Chloride (PVC) Polyvinyl Chloride (PVC)Form: Semi-finished sheet product. Semi-finished sheet product.Thickness: White available in 1, 2, 3, 4, 5, 6, 8, 10 & 13mm. White available in 3, 5 & 10mmColours available in 3 & 5mm.Colours available in 3 & 5mm.Smell: Odourless OdourlessMoisture absorption after 10 12 Ω4 x 10 15 Ωcm2.4 (for 1kHz)0.013 (for 1kHz)600 CPIStandard sheet sizes: Foamalux 2440 x 1220mm3050 x 1220mm3050 x 1560mm3050 x 2050mmFoamalux Ultra 2440 x 1220mmOther sizes are available to ordersubject to minimum quantities.Tolerances:Length:-0, +10mmWidth:-0, +3mmThicknessess: ± 5%8

FOAMALUXPRODUCTGUIDEFIRE PERFORMANCESURFACE PROTECTION & PACKAGINGSTORAGEFIRE PERFORMANCEFoamalux and Foamalux Ultra achieve excellentresults when tested using several national standardtest methods. Test certificates relating to the resultssummarised below are available on request.FOAMALUXCountry Test Method ResultBelgium NBN S21-203 A1France NF P 92-507 M1Germany DIN 4102 B1ItalyCSE RF2 /75/A,RF3/77 Class 1Spain UNE 93.727-90 Class 1UK BS 476 Part 7 Class 1USA UL-94 94V-0Foamalux Ultra has achieved Class 1 SurfaceSpread of Flame designation when tested underBS 476: Part 7: 1987 in the UK.SURFACE PROTECTION& PACKAGINGNormally all sizes and colours have an easily removedprotective polyethylene surface film, branded withthe Foamalux or Foamalux Ultra logo, appliedto one side.Sheets, whether stored indoors or outdoors,should be laid horizontally on a flat clean surface,for example, a solid topped pallet or wooden sheetraised from the floor or ground. Under the totalweight of sheet loaded on to it, this support mustnot distort, or distortion of the sheet could occurduring longer storage periods.Standing sheets on ends or sides, even for shortperiods, should be avoided. Coloured sheets shouldbe stored in their protective cardboard sleeves.Do not store indoors close to heat sources,for example, radiant heaters or boilers.Where storage outdoors cannot be avoided, atall times the stack of sheets should be completelyenclosed within a reflective waterproof cover,placed over wooden battens on top of the stackto avoid contact with the sheet surface. The covershould be secured to protect the stack against sun,wind and rain and the stack should be ventilatedto avoid heat build-up.All Foamalux and Foamalux Ultra sheets are factorypackaged to ensure they are received by the userin pristine condition. The sheets should be similarlyprotected or packaged at all stages of processingto ensure the quality of finished items.STORAGEFoamalux and Foamalux Ultra, in common with allother PVC sheet materials, are best stored indoors,away from direct sunlight, in a cool dry store. Thetemperature of uncovered stacked sheets in directsunlight can rise to levels which will be detrimentalto the material: the presence of moisture betweensheets can add to damage.9

FOAMALUXPRODUCTGUIDEHANDLINGSAFETY, WASTE DISPOSALHANDLINGFoamalux and Foamalux Ultra are relatively flexiblematerials but, if lifted or carried incorrectly, they canbe stressed beyond their flexible limits and cracked.Sheets and cut panels should not be dragged off astack but lifted up directly and set down directly.Surfaces on which sheets are set must be clean toavoid damage. When carrying, sheets should beturned on edge and held top and bottom. It willrequire more than one person to carry a largesheet or panel. Particular care should be taken withpanels which have been processed, for example,screen printed.SAFETYFoamalux and Foamalux Ultra are rigid foam PVCsheets extruded from polyvinyl chloride. They arenot subject to the laws governing the use ofdangerous materials or chemicals.No special protective measures are neededwhen transporting or handling the material.When working with the material care must betaken to protect eyes and avoid inhalation of dust.Foamalux and Foamalux Ultra sheets do notconstitute fire, explosion or toxic hazard material.In case of a fire involving Foamalux, Foamalux Ultraor any other PVC material, water, foam and carbondioxide extinguishers may be used. Burning causesnoxious fumes to be released eg. hydrochloricacid, carbon monoxide. Do not breathedecomposition products. When decompositionproducts have been accidentally inhaled, medicalassistance is required.WASTE DISPOSALDo not dispose of Foamalux or Foamalux Ultraby burning. They form an inert waste and canbe used as landfill, with no harmful environmentaleffects. High temperature incineration may beused. Disposal through local plastics recyclersis possible.10

FOAMALUXPRODUCTGUIDEINDEXDESIGN FACTORSDESIGN FACTORSPageSUNLIGHT 12THERMAL MOVEMENT 13LOW TEMPERATURES 13WIND LOADING 14PRECIPITATION 14CHEMICAL & ENVIRONMENTAL ATTACK 14COMPONENT GEOMETRY 14PANEL ORIENTATION 1511

FOAMALUXPRODUCTGUIDEDESIGN FACTORSSUNLIGHTDESIGN FACTORSEvery material has its unique advantages and specificrestrictions in use. A satisfactory finished product inany material is achieved through due considerationat design of its properties, means of processing andfabrication and also of the environmental conditionsto which it will be subject in use.SUNLIGHTSunlight affects all materials, to varying degrees,by the action of the UV radiation component ofsunlight and by raising surface temperatures.FOAMALUXUltraviolet light attacks many materials, as is evidentby the fact that, for example, painted surfaces fade.Foamalux, like all other plastic materials, is affectedby UV light: a colour will change according to itscolourfastness and the quantity of radiation absorbed.In practical terms, all coloured foam PVC sheetswill fade, but this may be immaterial in short termoutdoor applications and is irrelevant where thepanel is completely coated with, for example, ink,paint or varnish.Brett Martin does not recommend the use ofFoamalux colours for exterior uses where extendedlife is expected. Exterior uses which demand colourretention of Foamalux for an extended period canbe satisfied by applying a transparent vinyl or acrylicfilm, or varnish.FOAMALUX ULTRAThe key constituent of Foamalux Ultra is theco-extruded surface layer, derived from a PVCformulation and offering enhanced exteriorperformance. The UV protection afforded by thishigh gloss layer means that Foamalux Ultra, as wellas being suitable for internal use, is also ideal forexternal applications without the need foradditional protection. While it is impossible tocompletely eliminate change, Foamalux Ultra willretain its colouring with minimal change over anextended period of weathering. The rate of changeis dependent on a number of factors includingorientation and air quality.SURFACE TEMPERATURE EFFECTSAt moderate ambient air temperatures, 25°Cto 35°C, material surfaces can, depending oncolour and duration of exposure to direct sunlight,reach temperatures which would adversely affectany PVC sheet materal causing, for example,permanent buckling.SURFACE TEMPERATURES IN DIRECT SUNLIGHTSurface ColourTypical Temperature (°C)Black 80Dark Blue 68Grey 67Red 68Green 70Yellow 57White 40The maximum surface temperature for Foamaluxand Foamalux Ultra in service is 60°C. For exterioruse, lighter colours, or darker panels predominantlycovered with light coloured laminates, paints orinks, are best suited.Applications using extensive darker colouredpanels, or panels with dark coloured laminates,paints or inks, when exposed to sunlight mayachieve undesirably high temperatures.Small darker coloured panels or componentsare less liable to damage.Use behind glass requires adequate spacing fromthe glass and ventilation as, in a relatively enclosedspace, temperatures may get high enough tocause distortion.Internal applications require careful positioningin relation to heat sources, for example, radiantheaters or artificial lighting, which could producepanel distortion.12

FOAMALUXPRODUCTGUIDETHERMAL MOVEMENTLOW TEMPERATURESTHERMAL MOVEMENTChanges in temperature produce thermalmovement in Foamalux and Foamalux Ultra panels.The amount of movement is a product of the sheetdimensions, temperature change and the coefficientof linear expansion, 0.068mm/m°C.A 2440mm long panel will expand by 3.71mmas the temperature rises from 7°C to 27°C, atemperature differential of twenty degrees.In practice, Foamalux and Foamalux Ultra will beused in conjunction with many common buildingand accessory materials, the thermal expansionproperties of which must also be taken intoconsideration. The graph below illustrates the relativecoefficients for various materials. Foamalux clearlyexpands much more than timber, concrete,brickwork and metals when their temperatureis changed by the same amount.Significant temperature changes will occur in allexterior applications; there may also be internalapplications where variation in temperature isconsiderable. Thermal movement must thereforealways be accomodated in whatever means offixing is used. In Appendix 1 examples are given ofhow to calculate changes in sheet dimensions withtemperature change. Adequate fixing hole and slotsizes which will accomodate thermal movement aregiven in Appendix 4.The service temperature range limits, -20°C and+ 60°C, form the basis for the overall temperaturedifferential range of eighty degrees.LOW TEMPERATURESAs temperatures fall to freezing point and below,all PVC sheet materials become less pliable andmore brittle, therefore more susceptible to damagethrough rough handling and impact.Foamalux and Foamalux Ultra should be handledwith care in cold weather; all knocks and excessivetwisting and bending should be avoided.When cutting, drilling or performing any otheroperations, care must be taken in colder conditions.13

FOAMALUXPRODUCTGUIDEWIND LOADING, PRECIPITATIONCHEMICAL & ENVIRONMENTAL ATTACKCOMPONENT GEOMETRYWIND LOADINGAny panel mounted outside a building will besubject to wind loading. Panels mounted on wallswill not be critically affected by positive windpressures which force the sheet against the wall:however, negative or suction pressures will tendto pull the sheet away from the wall.In many external applications eg. where panelsare edge mounted in frames, they will be subjectto wind pressures from both sides.When designing an external application, windloads should be estimated and provision madefor secure means of fixing. For example, the fixingspacing should be as recommended on page 27and the diameter of the washer on the fixingshould be at least two times that of the hole drilledfor the fixing shank.COMPONENT GEOMETRYSharp corners and notches in thermoplasticcomponents assist in the initiation and propagationof cracks, particularly if a component is understress. Creases, grooves and sharp bends also formpotential weaknesses. Component shapes shouldexclude such features; all internal and externalcorners or changes in direction should followa smooth radiused profile.Where designs involve hot bending of sheets, radiishould ideally be not less than two and a half timesthe sheet thickness.Wind loads can be estimated using BS CP3:Chapter V: Part 2.PRECIPITATIONAll panels in external situations will be subject toprecipitation in the form of rain, sleet, snow andhail. Foamalux and Foamalux Ultra do not absorbmoisture from precipitation: they will not thereforedegrade or deteriorate in the presence of moisture.Hail storms may cause damage through impactof large hail stones on cold panels.CHEMICAL &ENVIRONMENTAL ATTACKThe base material for Foamalux and Foamalux Ultra,PVC, is highly resistant to attack from chemicalsand from pollutants in the atmosphere.Contact with solvents and wet wood preservativesmust be avoided. A listing of resistance to a rangeof chemicals at 23°C is given in Appendix 2.14

FOAMALUXPRODUCTGUIDEPANEL ORIENTATIONPANEL ORIENTATIONPanel orientation should be considered whenmounting, for example, rectangular panels by onlyone short edge in external applications. Extrudedmaterials generally have fractionally greater flexuralstrength, and therefore resistance to bending, inthe direction of extrusion. The protective film hasthe brand running across the direction of extrusion,providing ease of identification for correct cuttingof panels for such applications.15

FOAMALUXPRODUCTGUIDEINDEXMACHINING OPERATIONSMACHINING OPERATIONS PageCUTTING, SHAPING & FINISHING 18CUTTING 18GUILLOTINING 18DIE CUTTING 18SAWING 18DRILLING 19MILLING & ROUTING 19FINISHING 1917

FOAMALUXPRODUCTGUIDEMACHINING OPERATIONSCUTTING, GUILLOTINING,DIE CUTTING, SAWINGMACHINING OPERATIONSFoamalux and Foamalux Ultra are easy materialsto work with, using basic wood and metalworking tools.When working with any power tool, the sheettemperatures must be kept below the materialsoftening point of 70°C. Compressed air is asuitable and easy to apply coolant. Efficient removalof dust and swarf from the cutting tool helpsto lower temperatures. These measures assistin obtaining a good quality cut finish.In general, machining operations require acombination of low feed speed and depth of cuttogether with a high cutting speed. Correct toolgeometry is also important. The recommendationsgiven for tool geometries and speeds should beused as a guide: some experimenting may berequired to obtain best results.It is necessary to have an effective means ofremoving dust produced by machining operationsfrom the operator’s environment.CUTTING, SHAPING & FINISHINGDifferent means of cutting are appropriate forvarious thicknesses, ranging from hand tools topower saws.CUTTINGSheets 1mm and 2mm thick can be cut with shears:sheets 1-3mm thick can be cut with a craft knife:preheated sheets are easiest to cut. Sheetexceeding 3mm in thickness should be sawn.DIE CUTTINGFlat shapes with complex outlines can be die cutfrom thinner sheets - up to 4mm thick - usingsharp, accurately set, steel rule dies: best resultsare obtainable by preheating sheets to a maximumof 35°C; however, cut shapes should be placedbetween flat metal plates to cool, avoiding distortion.When designing components to be die cut, narrowsections and radii less than 3mm should be avoided.Sheets thicker than 4mm can be die cut providedthey are preheated and component radii are atleast equal to sheet thickness. Edge finishing maybe required.SAWINGBlades designed for cutting plastics are ideal forcutting Foamalux and Foamalux Ultra, as are mosttypes of wood saws - band, bench, circular, hand,jig and wall saws.Blades must be sharp, with a slight side set. Holdand support sheets to avoid stress and vibration,particularly in cold conditions. Blunt blades and veryfine tooth metal cutting blades, or incorrectly heldmaterial, produce an unsatisfactory finish.Blades should always cut down into the glosssurface of Foamalux Ultra.When using power saws, clear swarf and avoidheat build up at the cut to produce clean cuts.GUILLOTININGGuillotines can be used for rough cutting but arenot usually employed to finish-cut as their actioncompresses the sheet and can give a poor edgefinish eg. permanent edge distortion: cracks canalso be initiated in cold sheets.Guillotines with blades heated to around 160°Cgive a good quality cut edge with less possibilityof compressing or otherwise damaging thesheet edge.Angle º10°-15° circular saw30°-40° band sawRake angle † 0-8°Tooth pitch t5-15mm circular saw2-8mm band sawCircumference speed 1000-3000m/min.Feed speed6-30m/min.18

FOAMALUXPRODUCTGUIDEDRILLINGMILLING & ROUTINGFINISHINGDRILLINGSheet thickness and hole diameter requireddetermine the appropriate drill type. It is moredifficult to drill large holes in thinner sheets thansmall holes in thicker sheets. Thin sheets requirea high drill speed and low feed speed. Slower feedspeeds are used in deeper holes to minimise heatbuild up.Cutting tools must be capable of clearing largequantities of chips and cut depths and feed speedsmust not be too high to avoid heat build up andpoor edge finish.Cutters with single or twin cutting edges aremost suitable.Standard twist bits for metal are suitable forholes up to 12mm diameter in all thicknesses.Holes over 12mm in diameter can be drilled withflat bits, normally used for drilling wood. Above25mm diameter it is necessary to use hole sawsor circular cutters.Relief angle ‡ 0-15°Cutting speedup to 18000 rpmFeed speed0.3-0.5mm /rev.Tip angle o 100° - 110°Helix angle † 30°Drill speed1000 - 3000 rpmFeed speed0.2 - 0.5mm /rev.FINISHINGSheet edges can be finished by filing, sanding, grinding,planing or using a deburring tool, for example, a flatsteel edge scraper. Such finishing operations on thesheet surfaces will expose the inner cell structurewhich will be undesirable in most applications.Glossy surface finishes can be obtained using softbuffing wheels and applying polishing compound,but avoid abrading the surface.MILLING & ROUTINGAll types of milling machines and routers can beused to machine Foamalux and Foamalux Ultraif suitable tool geometry and cutting conditionsare used.Vacuum clamping machines are ideal as they areless likely to mark the surface than mechanicalclamping. Where sheets are mechanically clamped,load spreading pads should be used to avoidsurface marks.19

FOAMALUXPRODUCTGUIDEINDEXFORMING, FABRICATION & BONDINGFORMING, FABRICATION& BONDINGPageFOLDING 22DRAPE FORMING 23THERMOFORMING 23HOT AIR WELDING 25HOT PLATE WELDING 26STRUCTURES & FRAMES 26MECHANICAL FASTENING 27ADHESIVES 2821

FOAMALUXPRODUCTGUIDEFORMING, FABRICATION & BONDINGFOLDINGFORMING, FABRICATION& BONDINGMany processing operations involve heating.Foamalux and Foamalux Ultra are thermoplasticmaterials which attain an elastic state and aretherefore formable at material temperatures inthe range 115-135°C. The panel to be shaped orformed requires even heating throughout its areaand thickness. The component formed in theelastic state, when cooled slowly to a rigid statein the forming device, retains the formed shape.Heat sources can be hot air blowers, hot gaswelders, hot air circulating ovens and infra-redpanel heaters: all must have controls which enablegood regulation of their temperature and thatof the Foamalux.FOLDINGCold folding is not practical as the materials willstress and crack.Prior to folding, localised strip heating to about130°C is required. Heat the material for a distanceequivalent to three times the sheet thickness oneach side of the fold centre line.When heating is complete and the required shapeproduced, it must be allowed to cool on theforming equipment before handling or furtherprocessing, to avoid warping.Foamalux and Foamalux Ultra can be folded on asimple jig fitted with a forming tool having a radiusof about two and a half times the sheet thickness.Heating of one side will usually be enough forsheets up to 3mm thick: above this thickness heatshould be applied to both sides, reducing heatingtimes and the possibility of surface damage.Using radiant heat, a heating time of 20 secondsfor each 1mm of sheet thickness and using an oven,a heating time of 40 seconds for each 1mmthickness of sheet are reasonable starting pointsfrom which to develop.Some experimentation will always be required toobtain optimum temperatures for forming, thesebeing a function of sheet thickness and the specificforming operation: sheet colour and atmosphericconditions also have some influence.It is essential to ensure that all panels are free fromdust, oil and any other contaminants prior to anyforming operation, as these will detract from thequality of the finished product.As Foamalux and Foamalux Ultra are cellularmaterials they are not suitable for formingoperations which involve excessive stretching inthe elastic state. This will cause rupture of the cellsand blemishing of the external surface.22

FOAMALUXPRODUCTGUIDEDRAPE FORMINGTHERMOFORMINGDRAPE FORMINGWhere a specific thickness of Foamalux orFoamalux Ultra is to be curved to a smallerdiameter than is possible by cold bending, or it isrequired to form a simple curved skin, it is possibleto do this by softening a panel to an elastic state,draping over an appropriately shaped patternand retaining it until cooled and rigid.THERMOFORMINGComponents which are relatively simple and shallowin form are thermoformable from Foamalux andFoamalux Ultra heated to an elastic state.Air-pressure forming is possible at about 130°Cand pressures of about 2 bar and vacuum formingat about 170°C. As the material has relatively lowdensity, heating and cooling cycles are faster than withsolid thermoplastics. Higher temperatures enhancedefinition but at the expense of surface finish.Most industrial press and vacuum formers forthermoplastics are suitable. Best results are achievablefrom machines which controllably heat both sides ofthe sheet. Large area panels and thick panels needsome air pressure support during heating to avoid sag.Prior conditioning, by suspending in an air circulatingoven at about 130°C, removes inherent stresses.23

FOAMALUXPRODUCTGUIDETHERMOFORMINGMale moulds are suitable for vacuum forming,female moulds for vacuum and pressure forming.Secure clamping of the sheet during forming isessential to avoid shrinking: components must becompletely rigid before removing from the mould.VACUUM FORMING IN A FEMALE TOOLWhen an item involves screen printing andthermoforming for its production, the thermoformingprocessess should always precede the printing.PRESSURE FORMING IN A FEMALE TOOLVACUUM FORMING IN A MALE TOOL24

FOAMALUXPRODUCTGUIDEHOT AIR WELDINGWELDINGHot air welding and butt welding are mostcommonly used in fabrication. The equipment,welding rods and skills employed for welding solidthermoplastic sheets are suitable.SINGLE BEVEL CORNER WELDHOT AIR WELDINGTypical joints and the necessary panel preparationsare illustrated in the diagrams.WELDING TECHNIQUESINGLE BEVEL BUTT WELDDOUBLE BEVEL BUTT WELDSINGLE V BUTT WELDDOUBLE V BUTT WELDAir temperatures should be about 250°C toplasticise the sheet and welding rod sufficientlyfor effective bonding. Welding speeds of250-300mm/minute should avoid excessiveheating which will damage the sheet cell structure.Greater speed can be achieved with high speedwelding nozzles. Where multiple welds of a jointare necessary, the joint and surrounding areashould be allowed to cool between welds: coolingbetween stages in fabrication is necessary to avoiddistortion when the component is moved.25

FOAMALUXPRODUCTGUIDEHOT PLATE WELDINGSTRUCTURES & FRAMESHOT PLATE WELDINGButt welding of edges of sheets thicker than 3mmis possible using hot plate welding techniques.Sheet edges are plasticised through contact, underslight pressure, 0.05 - 0.07N/mm 2 , with a flat plateheater at a temperature of about 220°C.A welded join is formed by withdrawing the tool,pressing the plasticised edges together undercontrolled pressure, 0.2- 0.27N/mm 2 , and cooling.STRUCTURES & FRAMESIn practice Foamalux and Foamalux Ultra are fixedto structures and frames made from many materials,most commonly wood and metals. In the designof these, the differences in thermal expansionsmust be accomodated, for example, whencalculating sizes for fixing holes. An illustration ofa typical calculation is given in Appendix 1.Fixings should be placed at centres not exceedingthose recommended on page 27.Where large and relatively heavy panels are beingfixed, the panels should be suspended from a rowof fixings located near to the panel top, allowing itto expand down and to each side with temperaturechange. A large and relatively heavy panel mountedwith most of its weight bearing on fixings near thebottom edge could distort at elevated temperatures.Large panels mounted on external walls should bespaced from the wall surface using battens tomaintain a ventilating air gap of about 20mm behindthe panel. Direct mounting of the panels to thewalls could result in distortion due to heat build up.26

FOAMALUXPRODUCTGUIDEMECHANICAL FASTENINGMECHANICAL FASTENINGPanels can be fixed to supporting structures usingscrews, rivets or nails. Screws are most suitable asthey are most controllable: tightening a screw andthen backing it off slightly allows the panel to movewith temperature changes without deformation.WOOD SCREW FIXINGNails and rivets can be used with small panelsor in internal applications where there is littlethermal movement since temperature differentialsare small.In all cases holes must be predrilled oversizethrough the panel to accommodate thermalmovement. This in turn necessitates the use ofan oversize washer on the fastener to provideadequate retention of the sheet and spread theload. Countersunk screws must never be usedwithout a recessed washer.Holes or slots in a panel to accomodate fastenersshould always be at least 25mm from the panel edge.Appendix 4 gives details of appropriate hole,or slot and washer size for given sheet dimensionsand fixing shank diameters.Self tapping screws can be used to mount lightweightitems to panels thicker than 6mm.BOLT FIXINGFasteners should be spaced at the separationsgiven for each thickness of panel.W = Washer Diameterh = Hole Diameterb = Fixing Shank DiameterThicknessFastener Spacing (mm)1mm 100 - 1502mm 150 - 2503mm 250 - 3504mm 350 - 5005mm 5006mm 5008mm 50010mm 50027

FOAMALUXPRODUCTGUIDEADHESIVESADHESIVESRecommendations on adhesives are made onthe basis of tests, following each manufacturer’srecommendations on surface preparation, bondingconditions, application of primers and adhesives.The user should also satisfy himself, preferably bytesting, that any adhesive or bonding material will besuitable for his specific application. The user shouldat all times follow the adhesive manufacturer’srecommendations as to suitability, surfacepreparation, use of primers, application methods,curing times and conditions to be satisfied foreffective bonding.Manufacturers’ health and safety precautions shouldalso be observed.2. Contact Adhesives - These are used whenbonding sheets of Foamalux and Foamalux Ultrato flat surfaces and are based on solvent solutionsof synthetic rubbers - eg. polychlorophene or nitrilerubber. Both surfaces to be joined should haveadhesive applied: after solvent evaporation bringthe two surfaces together under pressure.Double sided pressure sensitive adhesive tapesare a very efficient and effective means of attachingflat panels to each other and to support structuresand of attaching other flat materials to Foamalux.Please refer to the Brett Martin web site or contactthe Technical Department for furtherinformation.BONDING FOAMALUX ANDFOAMALUX ULTRA TOGETHERSolvent Adhesives - Based on methyl ethylketone (MEK), tetrahydrofuran (THF) andcyclohexanone.Adhesives set as solvents evaporate; successfulbonding requires application of pressure andcomponents fitted together accurately as solventbased adhesives will not fill gaps.BONDING FOAMALUX &FOAMALUX ULTRA TOOTHER MATERIALS1. Reaction Adhesives - There are two basictypes: 1-part adhesives set by reacting withmoisture; 2-part adhesives set by the reactionbetween a chemical base and a catalyst.• 1-part adhesives - polyurethane or cyanoacrylatebased - set very quickly and are ideal whensmall components, particularly of wood,metals and plastics, are bonded to Foamaluxand Foamalux Ultra.• 2-part adhesives - polyester, polyurethane,polymethacrylate or epoxy based - are slowerto cure, but ideal for bonding Foamalux andFoamalux Ultra to metals, wood and masonry.28

FOAMALUXPRODUCTGUIDEINDEXSUBSTRATE APPLICATIONSSUBSTRATE APPLICATIONS PagePREPARATION 30STATIC ELECTRICITY 30TOLERANCES 30PAINTING & VARNISHING 30VINYL GRAPHICS 31LAMINATION 31PRINTING 3129

FOAMALUXPRODUCTGUIDESUBSTRATE APPLICATIONSPREPARATION, STATIC ELECTRICITYTOLERANCES, PAINTING & VARNISHINGSUBSTRATE APPLICATIONSFoamalux and Foamalux Ultra surface finish andconsistency of thickness make them ideal substratematerials for silk screen printing, photographicmounting and laminating in the production of signs,displays and point of sale equipment. As they do notcrease or bend easily they are superior substratesto card and board materials in many instances.PREPARATIONA perfectly clean surface is an essentialprerequisite to any substrate use. Film protectionat manufacture maintains surface cleanlinessand should be retained until the latest possiblestage in processing.Prior to processing, eg. adhesive bonding orprinting, the user must satisfy himself by trial thatthe qualities of Foamalux and Foamalux Ultra areappropriate for the intended use and whether anyadditional surface cleaning or preparation maybe required.Cleaning by wiping with a soapy water solutionwill remove dust from cutting or prolonged storage.Residual soapy film may affect keying of inksor vinyls and should be removed using a lint freewipe moistened with aliphatic solvent - heptaneor octane. These solvents will remove greasydeposits and dust or dirt adhering to the surface,as will methyl alcohol or methylated spirits.Wipe in one direction only; wiping with a circularmotion can create additional static charge.Abrasive and alkali cleaners will harm the surfacefinish and must not be used. Cleaners must notcontain silicone compounds, as residues of theseprevent vinyl inks adhering.STATIC ELECTRICITYStatic electricity is produced when the protectivefilm is stripped off and during processing andhandling. It is necessary to remove it from panelswhich are to be screen printed. Static chargescan be neutralised temporarily in several ways.Isopropyl alcohol solution applied to the sheetsurface by wipe or spray evaporates quickly in air,leaving an antistatic film which is effective for aconsiderable period of time. Wiping with soapywater solution has a charge neutralising effect.The static charge can also be neutralised by blowingionised air on to the panel or component.Foamalux AS uses a special formulation to resistthe build up of static charge. Please contact ourtechnical department for full details.TOLERANCESWhen processing eg. screen printing and tightertolerances are required, the user, when ordering,must make allowances for truing panels to theaccuracy required for processing.PAINTING & VARNISHINGSheet surfaces are excellent for painting andvarnishing. All paint application techniques - brush,roller, spray - can be used. Surface preparationinstructions should again be followed. Vinyl, acrylicand two part polyurethane based paints are ideal -manufacturers’ application and safety directionsshould be followed.30

FOAMALUXPRODUCTGUIDESUBSTRATE APPLICATIONSVINYL GRAPHICS,LAMINATION & PRINTINGVINYL GRAPHICSDecorative and lettering / script graphics can beapplied to Foamalux and Foamalux Ultra as bothmaterials form very rigid and stable substrates.Their surface quality ensures excellent results freefrom visual distortion.All materials used in the application process mustbe dust and moisture free to avoid surface bumpsand blisters. Application pressure must be evenand strong enough to expel air from the vinyl butexcessive pressure can lead to distortion of thegraphic and may cause wrinkles.LAMINATIONAll material used in the laminating process mustbe dust and moisture free while pressure mustbe even and strong enough to expel air acrossthe sheet width.PRINTINGThe surface quality on both materials is ideal forscreen printing in particular: vinyl or vinyl/acrylicbased inks, with their own thinners, should be used.Surface preparation instructions should be thorough,as dust, dirt, static electricity, or undesirable residuescan affect the finished print quality. A list of inkmanufacturers is given in Appendix 3.Foamalux and Foamalux Ultra are semi-finishedmaterials, manufactured in a continuous processsubject to the manufacturing tolerances appropriatefor semi-finished products. When tight tolerancesare required, allowances must be made, whenordering, for truing panels to the accuracy requiredfor processing.Roller laminating machines are essential for largersizes and volumes of panels as ideal rolltemperatures, pressures and laminating speed canbe determined and accurately controlled to suitthe sheet thickness and the material being applied.Hand laminating is suitable only for small sizesand runs of panels.Laminating on a clear film protects the print orgraphic surface while matt finishes can reduce glare.Application of films which require hightemperatures should be avoided as this couldlead to buckling of the sheet.Photomounting to Foamalux and Foamalux Ultragives very high quality results due to the excellentsurface finishes and stability of the materials31

FOAMALUXPRODUCTGUIDEINDEXAPPENDICESAPPENDICESPageAPPENDIX 1 - THERMAL MOVEMENTCALCULATIONS 34APPENDIX 2 - CHEMICAL RESISTANCE 36APPENDIX 3 - ADHESIVES MANUFACTURERS 40INK MANUFACTURERS 40APPENDIX 4 - HOLE, SLOT & WASHER SIZES 4033

FOAMALUXPRODUCTGUIDEAPPENDIX 1THERMAL MOVEMENT CALCULATIONSEXAMPLE 1A Foamalux sheet is to be used to form a signpanel on the outside of a building. It is expectedthat the panel temperature will be as low as -12°Cin winter and as high as 31°C in summer. The panelmeasures 1.2m wide and 1.5m high in a workshopat a temperature of 18°C. The panel is to be hungfrom its top edge with a fixed point at the centre,so that thermal movement takes place from thetop down and from the centre horizontally to eachside. Estimate the clearance required in retainingchannels which will frame the bottom and sidesof the sheet.1. WidthDimension change in cooling from 18°C to -12°CTemperature change = 30°CInitial width = 1.2mExpansion coefficient = 0.068mm/m°CReduction in width = 1.2 x 30 x 0.068 = 2.45mm2. LengthDimension change in cooling from 18°C to -12°CTemperature change = 30°CInitial length = 1.5mExpansion coefficient = 0.068mm/m°CReduction in length = 1.5 x 30 x 0.068 = 3.06mmDimension change in heating from 18°C to 31°CTemperature change = 13°CInitial length = 1.5mExpansion coefficient = 0.068mm/m°CIncrease in length = 1.5 x 13 x 0.068 = 1.33mmTotal length change = δL = 3.06 + 1.33 = 4.39mm,say 5mm when rounded up to the nearest mm.As the sheet is fixed at the top it will movevertically 5mm, ie. 5mm clearance is required inbottom channel.Dimension change in heating from 18°C to 31°CTemperature change = 13°CInitial width = 1.2mExpansion coefficient = 0.068mm/m°CIncrease in width = 1.2 x 13 x 0.068 = 1.06mmTotal width change = δw = 2.45 + 1.06 = 3.51mm,say 4mm when rounded up to the nearest mm.As the sheet is fixed at its centre it will move halfof this distance each side of the fixed point,ie. 2mm clearance is required in each side channel.34

FOAMALUXPRODUCTGUIDEAPPENDIX 1THERMAL MOVEMENT CALCULATIONSEXAMPLE 2The Foamalux sheet in the previous example isto be fixed with a row of screws along its topedge, with outer screws 50mm in from sheet sides.Estimate the size of slot required to accommodatethermal movement. The screws have a shankdiameter of 6mm.Sheet width 1.2mOuter slot separaration =1.2 - (2 x 0.05) = 1.1mDistance from fixed point to slot centre = 0.55mThis distance contracts as sheet cools from 18°Cto -12°C by an amount 0.55 x 30 x 0.068 = 1.12mmThis distance expands as sheet heats up from 18°Cto 31°C by an amount 0.55 x 13 x 0.068 = 0.49mm8.24mmThe fixing must be centred in a slot with a lengthwhich can accommodate, at least, the greateramount of thermal movement. In this case,the greater movement is 1.12mm from cooling.Minimum slot length = fixing shank diameter +(2 x greater thermal movement)= 6 + (2 x 1.12) = 8.24mm35

FOAMALUXPRODUCTGUIDEAPPENDIX 2CHEMICAL RESISTANCECHEMICAL RESISTANCE OF FOAMALUX & FOAMALUX ULTRAKEY:+ good resistance- poor resistanceChemical name Resistance at 23°CAcetaldehyde 40% +Acetaldehyde 100 % -Acetic acid 10% +Acetic acid 20% +Acetic acid 80% +Acetic acid, glacial +Acetic anhydride -Acetone -Adipic acid +Allyl alcohol 96% +Allyl chloride -Alum +Aluminium alum +Aluminium chloride +Aluminium fluoride +Aluminium hydroxide +Aluminium oxychloride +Aluminium nitrate +Aluminium sulphate +Ammonia gas (dry) +Ammonia, liquid -Ammonium acetate +Ammonium alum +Ammonium bifluoride +Ammonium carbonate +Ammonium chloride +Ammonium fluoride 25% +Ammonium hydroxide +Ammonium metaphosphate +Ammonium nitrate +Ammonium persulphate +Ammonium phosphate +Ammonium sulphate +Ammonium sulphide +Ammonium thiocyanate +Amyl acetate -Amyl alcohol +Amyl chloride -Aniline -Aniline chlorohydrate -Aniline hydrochloride -Anthraquinone sulphonic acid +Antimony trichloride +Aqua regia +Aromatic hydrocarbons -Arsenic acid 80% +Arylsulphonic acid +Barium carbonate +Barium chloride +Barium hydroxide +Barium sulphate +Barium sulphide +Beer +Beer sugar liquors +Benzaldehyde 10% +Benzaldehyde, above 10% -Benzene -Benzine +Benzoic acid +Bismuth carbonate +Bleach 12% CI +Borax +Boric acid +Bromic acid +Bromine liquid -Bromine water +Butadiene +Butane +Butanol normal +Butanol iso +Butyl acetate -Butyl phenol +Butyric acid +Cadmium cyanide +Calcium bisulphite +Calcium carbonate +Calcium chlorate +Calcium chloride +Calcium hydroxide +Calcium hypochlorite +Calcium nitrate +Calcium oxide +Calcium sulphate +Carbon disulphide -36

FOAMALUXPRODUCTGUIDEAPPENDIX 2CHEMICAL RESISTANCECarbon dioxide +Carbon monoxide +Carbon tetrachloride +Carbonic acid +Castor oil +Caustic potash +Caustic soda +Chloroacetic acid +Chloral hydrate +Choric acid 20% +Chlorine (dry) -Chlorine (wet) -Chlorine water +Chlorobenzene -Chloroform -Chlorosulphonic acid +Chrome alum +Chromic acid 10% +Chromic acid 50% -Citric acid +Copper carbonate +Copper chloride +Copper cyanide +Copper fluoride +Copper nitrate +Copper sulphate +Cottonseed oil +Cresol +Cresylic acid -Crotonaldehyde -Crude oil +Cupric fluoride +Cupric sulphate +Cuprous chloride +Cyclohexanol -Cyclohexanone -Detergents +Dextrin +Dextrose +Diazo salts +Diglycolic acid +Dimethylamine +Dioctyl phthalate -Disodium phosphate +Distilled water +Esters -Ethers -Ethyl acetate -Ethyl acrylate -Ethyl alcohol +Ethyl chloride -Ethyl ether -Ethylene bromide -Ethylene chlorohydrin -Ethylene dichloride -Ethylene glycol +Ethylene oxide -Fatty acids +Ferric chloride +Ferric hydroxide +Ferric nitrate +Ferric sulphate +Ferrous chloride +Fluoboric acid +Fluorine gas (wet) +Fluorine gas (dry) +Fluorosillicic acid 25% +Formaldehyde +Formic acid +Fructose +Fruit juices and pulp +Furfural -Gallic acid +Glucose +Glycerine +Glycol +Glycolic acid +Heptane +Hexane +Hexanol, tertiary +Hydrobromic acid 20% +Hydrochloric acid 10% +Hydrochloric acid 35% +Hydrocyanide acid +Hydrofluoric acid 50% +Hydrogen +Hydrogen peroxide 30% +Hydrogen peroxide 90% +Hydrogen phosphide +Hydrogen sulphide +Hydroquinone +Hydroxylamine sulphate +Hypochlorous acid +Iodine -37

FOAMALUXPRODUCTGUIDEAPPENDIX 2CHEMICAL RESISTANCEKerosene +Ketones -Lactic acid 25% +Lauric acid +Lauryl chloride +Lead acetate +Lead chloride +Lead sulphate +Lead tetraethyl +Linoleic acid +Linseed oil +Lithium bromide +Lubricating oil +Machine oil +Magnesium carbonate +Magnesium chloride +Magnesium citrate +Magnesium hydroxide +Magnesium nitrate +Magnesium sulphate +Maleic acid +Malic acid +Mercuric chloride +Mercuric cyanide +Mercurous nitrate +Mercury +Methyl alcohol +Methyl bromide -Methyl chloride -Methyl methacrylate -Methylene chloride -Methyl ethyl ketone -Methyl iso butyl ketone -Methyl sulphate +Methyl sulphuric acid +Milk +Mineral oils +Molasses +Monochloracetic acid +Muriatic acid +Naphtha +Napthalene -Natural gas +Nickel chloride +Nickel nitrate +Nickel sulphate +Nicotine +Nicotine acid +Nitric acid, anhydrous -Nitric acid 10% +Nitric acid 60% +Nitric acid 68% +Nitrobenzene -Nitrous oxide +Oils and fats, vegetable +Oleic acid +Oleum -Oxalic acid +Oxygen +Ozone +Palmitic acid +Paraffin +Perchloric acid 10% +Perchloric acid 15% +Perchloric acid 70% +Petrol +Petrol high octane +Phenol +Phenylhydrazine -Phenylhydrazine hydrochloride +Phosgene gas +Phosgene liquid -Phosphoric acid 10% +Phosphoric acid 85% +Phosphoric acid (yellow) +Phosphorus pentachloride +Phosphorus trichloride -Photographic solutions +Pictic acid -Potassium alum +Potassium bicarbonate +Potassium bichromate +Potassium borate +Potassium bromate +Potassium bromide +Potassium carbonate +Potassium chromate +Potassium chlorate +Potassium chloride +Potassium cyanide +Potassium dichromate +Potassium ferricyanide +Potassium ferrocyanide +Potassium fluoride +38

FOAMALUXPRODUCTGUIDEAPPENDIX 2CHEMICAL RESISTANCEPotassium hydroxide +Potassium nitrate +Potassium perborate +Potassium perchlorate +Potassium permanganate 10% +Potassium permanganate 25% +Potassium sulphate +Propane liquid +Propane gas +Propargyl alcohol +Propyl alcohol +Propylene dichloride -Plating solutions +Rochelle salts +Sea water +Selenic acid +Sewage +Sillicic acid +Silver cyanide +Silver nitrate +Silver plating solution +Silver sulphate +Soaps +Sodium acetate +Sodium alum +Sodium benzoate +Sodium bicarbonate +Sodium bisulphate +Sodium bisulphite +Sodium bromide +Sodium carbonate +Sodium chlorate +Sodium chloride +Sodium cyanide +Sodium dichromate +Sodium ferricyanide +Sodium ferrocyanide +Sodium fluoride +Sodium hydroxide 10% +Sodium hydroxide 50% +Sodium hypochlorite +Sodium nitrate +Sodium peroxide +Sodium sulphate +Sodium sulphide +Sodium sulphite +Stannic chloride +Stannous chloride +Starch +Stearic acid +Sulphur +Sulphur dioxide (dry) +Sulphur dioxide (wet) +Sulphur trioxide +Sulphuric acid 3% +Sulphuric acid 70% +Sulphuric acid 80% +Sulphuric acid 85% -Sulphurous acid +Tallow +Tall oil +Tannic acid +Tartaric acid +Tetraethyl lead +Tetrahydrofurane -Thionyl chloride -Terpineol +Titanium tetrachloride -Tanning liquors +Toluene -Transformer oil +Tributyl phosphate -Trichlorethylene -Triethanolamine +Trimethyl propane +Trisodium phosphate +Turpentine +Urea +Urine +Water - deionized +Water - distilled +Water - demineralized +Water - salt +Whiskey +Wines +Xylene -Yeast +Zinc chloride +Zinc nitrate +Zinc sulphate +39

FOAMALUXPRODUCTGUIDEAPPENDIX 3ADHESIVES MANUFACTURERSINK MANUFACTURERSAPPENDIX 4HOLE, SLOT & WASHER SIZESADHESIVES MANUFACTURERSLoctite (UK) LtdWatchmead, Welwyn Garden CityHerts, AL7 1JBTel: 01707 358800 Fax: 01707 3589003M United Kingdom plc3M HousePO Box 1, Market PlaceBracknell, Berkshire, RG12 1JUTel: 01344 858000 Fax: 01344 858278Stelmax Ltd21/23 Gloster Road,Martlesham Heath Industrial EstateNr. Ipswich, Suffolk, IP5 7RDTel: 01473 622265 Fax: 01473 610651Dunlop Adhesives LtdChester Road, Birmingham, B35 7ALTel: 0121 373 8101 Fax: 0121 384 2826Bostik LtdUlverscroft Road, Leicester, LE4 6BWTel: 0116 2510015 Fax: 0116 2531943Dow Corning HansilMeridian Business Park, Copsi DriveCoventry, CV5 9RGTel: 01676 528000 Fax: 01676 528101Evode LtdCommon Road, Stafford, ST16 3EHTel: 01785 257755 Fax: 01785 241615Henkel Chemicals LtdRoad 5, Winsford Industrial EstateWinsford, CW7 3QYTel: 020 8804 3343 Fax: 020 8443 2777INK MANUFACTURERSGibbons Inks & CoatingsScreen Division, 25 Deer Park Road, WimbledonLondon, SW19 3UETel: 020 8540 8531 Fax: 020 8542 5256Sericol LtdPatricia Way, Pysons Road Industrial EstateBroadstairs, Kent, CT10 2LETel: 01843 866668 Fax: 01843 872074Apollo Colours Ltd127 Nathan Way, West Tensmead Business ParkLondon, SE28 0ABTel: 020 8854 0017 Fax: 020 8316 6956HOLE, SLOT & WASHER SIZESThe following table gives minimum hole diametersor slot lengths, ‘D’ and corresponding washerdiameters, ‘W’, to be used for panel dimension ‘v’or ‘h’, assuming screw diameter ‘d’ and using amaximum temperature differential of 60°C.d = 4 d = 5 d = 6 d = 8 d = 10v,h D W D W D W D W D W200 5 10 6 12 7 14 9 18 11 22400 6 12 7 14 8 16 10 20 12 24600 7 14 8 16 9 18 11 22 13 26800 8 16 9 18 10 20 12 24 14 281000 9 18 10 20 11 22 13 26 15 301200 10 20 11 22 12 24 14 28 16 321400 11 22 12 24 13 26 15 30 17 341600 12 24 13 26 14 28 16 32 18 361800 12 24 13 26 14 28 16 32 18 362000 13 26 14 28 15 30 17 34 19 382200 14 28 15 30 16 32 18 36 20 402400 15 30 16 32 17 34 19 38 21 422600 16 32 17 34 18 36 20 40 22 442800 17 34 18 36 19 38 21 42 23 463000 18 36 19 38 20 40 22 44 24 48d = fixing shank diameterD = minimum hole diameter or slot widthW = minimum washer diameterv = vertical panel dimensionh = horizontal panel dimension40

All reasonable care has been taken in the compilation of the information contained within this literature.All recommendations on the use of our products are made without guarantee as conditions of use arebeyond the control of Brett Martin. It is the customer's responsibility to ensure that each product isfit for its intended purpose and that the actual conditions of use are suitable.Brett Martin pursues a policy of continuous product development and reserves the right to amendspecifications without prior notice.Copyright Brett Martin Ltd. July 2000

BRETT MARTIN LTD24 ROUGHFORT ROADMALLUSK, CO ANTRIMUK, BT36 4RBTEL: +44 (0) 28 9084 9999FAX: +44 (0) 28 9083 6666Email: mail@brettmartin.comBRETT MARTIN SEMI-FINISHED PRODUCTSLANGLEY ROADBURSCOUGH INDUSTRIAL ESTATEBURSCOUGH, LANCASHIREENGLAND, L40 8JRTEL: +44 (0) 1704 895345FAX: +44 (0) 1704 898628Email: semifinished@brettmartin.comBRETT MARTIN INTERNATIONAL BVNOORDMEERSTRAAT 132131 AD HOOFDDORPNETHERLANDSTEL: +31 (0) 23 5540955FAX: +31 (0) 23 5540966Email: international@brettmartin.comFOR THE LATEST INFORMATIONVISIT THE COMPANY’S WEB SITE:http://www.brettmartin.com618SF07023